Page 28 - 04. Subyek Engineering Materials - Manufacturing, Engineering and Technology SI 6th Edition - Serope Kalpakjian, Stephen Schmid (2009)

General Introduction
Although ironmaking began in the Middle East in about 1100 B.C., a major
milestone was the production of steel in Asia during the period 600-800 A.D. A wide
variety of materials continually began to be developed. Today, countless metallic and
nonmetallic materials with unique properties are available, including engineered mate-
rials and various advanced materials. Among the available materials are industrial or
high-tech ceramics, reinforced plastics, composite materials, and nanomaterials that
are now used in an extensive variety of products, ranging from prosthetic devices and
computers to supersonic aircraft.
Until the Industrial Revolution, which began in England in the 1750s and is also
called the First Industrial Revolution, goods had been produced in batches and re-
quired much reliance on manual labor in all phases of their production. The Second
Industrial Revolution is regarded by some as having begun in the mid-1900s with
the development of solid-state electronic devices and computers (Table 1.2).
Mechanization began in England and other countries of Europe, basically with the de-
velopment of textile machinery and machine tools for cutting metal. This technology
soon moved to the United States, where it continued to be further developed.
A major advance in manufacturing occurred in the early 1800s with the design,
production, and use of interchangeable parts, conceived by the American manufacturer
and inventor Eli Whitney (1765-1825). Prior to the introduction of interchangeable
parts, much hand fitting was necessary because no two parts could be made exactly
alike. By contrast, it is now taken for granted that a broken bolt can easily be replaced
with an identical one produced decades after the original. Further developments soon
followed, resulting in countless consumer and industrial products that we now cannot
imagine being without.
Beginning in the early 1940s, several milestones were reached in all aspects of
manufacturing, as can be observed by a detailed review of Table 1.2. Note particular-
ly the progress that has been made during the 20th century, compared with that
achieved during the 40-century period from 4000 B.C. to 1 B.C.
For example, in the Roman Empire (~500 B.C. to 476 A.D.), factories were
available for the mass production of glassware; however, the methods used were gen-
erally very slow, and much manpower was involved in handling the parts and oper-
ating the machinery. Today, production methods have advanced to such an extent
that (a) aluminum beverage cans are made at rates of more than 500 per minute,
with each can costing about four cents to make, (b) holes in sheet metal are punched
at rates of 800 holes per minute, and (c) incandescent light bulbs are made at rates
of more than 2000 bulbs per minute (see Example I.1), each costing less than one
dollar.

EXAMPLE l.| Incandescent Light Bulbs

The first incandescent lamp was made by TA. Edison The basic components of an incandescent
(1847-1931) in New _Iersey and was first lit in 1879. (meaning “glowing with heat”) light bulb are shown
A typical bulb then had a life of only about in Fig. I.2a. The light-emitting component is the
13.5 hours. Numerous improvements have since been filament, which, by the passage of current and due
made in both materials and production methods for to its electrical resistance, is heated to incandescence
making light bulbs, with the main purposes being in- to a temperature of 2200°-3000°C. Edison’s first
creasing their life and reducing production costs. This successful lamp had a carbon filament, although he
example briefly describes the typical sequence of meth- and others also had experimented with carbonized
ods used in manufacturing incandescent light bulbs. paper and metals such as osmium, itidium, and